Westerbeke 21.0KW EDE -50Hz, Operator'S Manual

Page 1: ...Hz 28 5KW EDE 60Hz 26KW EDE 50Hz 23 5KW EDE 50Hz 25 5KW EDE 60Hz 21 0KW EDE 50Hz WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEB SITE WWW WESTERBEKECOM...

Page 2: ...in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONEELSEEXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESH AIR IMMEDIATELY Ifsymptoms persist seek medical attention S...

Page 3: ...ar the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters...

Page 4: ...into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadlygas Ensure that the exhaust system is adequate to expel gases discharged from the...

Page 5: ...other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations...

Page 6: ...ad waterline will resull in raw water damage to the engine and possihl flooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterli...

Page 7: ...Starter Motor Troubleshooting 19 Wiring Diagram 52413 21 Engine Troubleshooting Chart 22 Alternator Testing 24 Battery Care 24 Glow Plugs 27 Wiring Diagrams 20 Engine Troubleshooting Chart 22 Alternat...

Page 8: ...KE LtN tH_ AIR BLEED PETCOC Ki DRIVE COVER DC ALTEIINAnIR FRDNT FLEXIBLE ISOLATED MOUNTS COOLANT RIGHT SIDE CONTROL LEFT SIDE Engines Generators 2 OIL FILL THERMOSTAT f INJIECTION PUMP 1lc LI L 11AW W...

Page 9: ...technical data parts lists manuals brochures and catalogs provided from sources other than WESTERBEKE are not within WESTERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFT...

Page 10: ...uires the same preventive maintenance as a gasoline engine The most important factors are proper ventilation and proper maintenance of the fuel lubricating and cooling systems Replacement of fuel and...

Page 11: ...roduce properties harmful to your engine SAE Oil Viscosity Grades For all temperature ranges SAE lOW 30 or SAE ISW 40 ENGINE COOLANT WESTERBEKE recommends a mixture of SO antifreeze and SO distilled w...

Page 12: ...s Visually examine the unit Look for loose or missing parta disconnected wires unattached hoses and check threaded connections Search for any fuet leaks __ I OIL FILL i II OIL FILTER V 2 1 S lg OIL FI...

Page 13: ...s will cycle in the following sequence o Engine Speed 1800 RPM oJ 2500 SCROLL Coolant Temperature 172F o 30 SCROLL NOTE During operation the color ofthe LCD display may vary Caused by heat this is nom...

Page 14: ...as mitch as 72 amp hours in a months time with no generator use It is not necessary to be concerned with this slight amperage draw during normal seaso al use However if the generator set is not to be...

Page 15: ...in three different lengths and two of these can be combined for a maximum run at 75 22 17M NOTE For additional information contact your local WESTERBEKE dealer 3 1 4 82 55MIII REMOTE PANEI PIG TAII 6...

Page 16: ...t draw requiredfor starting motors This starting amperage draw can be 3 to 5 times normal running amperage See GENERATOR INFORMATION in this manual GENERATOR ADJUSTMENTS Once the generator has been pl...

Page 17: ...tions Keep bolts nuts tight remain cool Check for loose belt tension Fuel Filter 0 0 0 0 0 0 Initial change at 50 hrs then change every 250 hrs Inlet Fuel Filter 0 0 0 0 0 Replace Starting Batteries 0...

Page 18: ...timing Compression see Engine Adjustments Adjust the Valve Clearances 0 Adjust Valve Clearances see ENGINEADJUSTMENTS Heat Exchanger 0 Remove have professionally cleaned and pressure tested Water tnj...

Page 19: ...th diesel before installing This will dramatically reduce the priming time needed to purge air from the engines fuel system before starting 5 Install the new cartridge and spin on real tight by hand 6...

Page 20: ...4 Replace the washer if necessary S Reassemble and install the strainer 6 Open the seacock 7 Run the engine and check for leaks NOTE Alsofollow the above procedure after having run hard aground If th...

Page 21: ...engine manifold level and should be easily accessible NOTE This tank with its short I U1I ofplastic wse is best located at or above the level ofthe engine smanifold CHANGING COOLANT The engine s cool...

Page 22: ...otate the thermostat assembly Loosen the hose clamp as shown and remove the three allen screws that hold down the thermostat housing cover the assembly can now be twisted enough to access the gasket a...

Page 23: ...stem tube Absence of W ilter flow indicates the pump has not primed itself properly NOTE Never allow the pump to run dry Even a short period ofdry running may destroy the impeller RAW WATER PUMP PN 52...

Page 24: ...owels and a plastic bag around the filter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Keep your engine clean Inspec...

Page 25: ...3 4TORN AFTER THE O RING CONTACTS THE BASE NOTE Westerbeke is not responsible for enginefailure due to incorrect installation ofthe Remote Oil Filter ACAUTION It is vital to install the oil lines cor...

Page 26: ...o testing make certain the ships batteries are at full charge and that the starting system wiring colmections temlinals are clean and tight Pay particular attention to tile growld wire connections on...

Page 27: ...arter will run the motor without engaging theflywheel Turn the starter switch on to provide thepower to the solenoid Hopefully it will create enough magneticfieldfor the arm to move even though the co...

Page 28: ...I I I I I I I I I r i Y i I __ _ WESTERBEKE 21 Eng ires Generators 52951 J It I I d I r I 1 1 I iii il I i G f II II I I _ I I II I I L_ _ _ __ I...

Page 29: ...uit and check circuit for shorts to ground 4 Check connection to starter solenoid and connection to engine ground stud Check battery cable connections 1 Check connection 2 Check that 12 volts are pres...

Page 30: ...lace 4 Ground connection 4 Check ground circuil 5 Faulty control module 5 Check plug connections replace Exhaust Temperature External Fault 1 Check sea water flow 1 Inspect thru hull fitting hose and...

Page 31: ...ld in order to maintain a proper system voltage The regulator design utilizes all silicon semi conductors and thick film assembly techniques After Ibe voltage has been adjusted to the proper regulatin...

Page 32: ...G BATTERY VOLTAGE IGNITION ON ENGINE TESTING THE OUTPUT CIRCUIT 1 Connect the positive probe to the output terminal Band connect the negative probe to ground 2 Wiggle the engine wiring harness while o...

Page 33: ...he voltage of the service battery this battery should have a voltage between 13 and 14 volts when the engine is running Ifnot there is a problem in the service battery charging circuit Troubleshoot th...

Page 34: ...y of the glow plug as shown A good glow plug will have a 1 0 1 5 ohm resistance Ibis method can be used with the plug in or out of the engine You can also use ao multimeter to test the power drain 8 9...

Page 35: ...rain rocker cover Rotate the engine crank manually and observe the valve operatidnfor cylinder 1 and bring the 1 piston up to Top Dead Center of the compression stroke Adjust the valves referencing th...

Page 36: ...sing a 17mm long socket remove the fuel return line in its entirety from the top of the injectors Take care not to lose the two sealing washers and banjo bolt that attaches the fuel return line to eac...

Page 37: ...ening manually rotate the engine crankshaft so as to position the flat of one of the ring gear s teeth directly under the opening Thread the MPU into the opening until it gently contacts the flat of t...

Page 38: ...doven 2 5Kw 12VDC direct dove Glow plugs sheathed type 400 600 includes glow plugs General Operating Temperature Fresh Water Pump Raw Water Pump System Capacity fresh water Raw Water Flow Rate at 1800...

Page 39: ...lation should be provided to maintain generatorcompartment temperatures below 104 F 40 C SPECIFICATIONS 28 5 23 5KW EDE AC GENERATOR Single Phase AC GENERATOR 3 Phase Single Phase Brushless six pole r...

Page 40: ...perage 3phase Low Voltage WYE 99 3 Amps Rating Volts AC 60 Hertz High Voltage WYE 49 6 Amps 0 Hz 11800 rpm 120 volts 275 amps DELTA 86 0 Amps 120 240 volts 275 137 5 amps Amperage 3phase High Voltage...

Page 41: ...check it with a portable meter and amp probe Generator Frequency Adjustment Frequency is a direct result of engine generator speed as indi cated by the following o When the generator is run at 1800 R...

Page 42: ...z L N 138 volts L N 10 12 2 4 6 9 0 1 3 5 7 11 N 1 1 L2 50 Hz L L 230 volts 50 Hz L N 115 volts 60 Hz L L 277 volts 60 Hz L N 138 volts Refer to Note 1 L 0 0 Nole 1 Single phase ampemge load The phase...

Page 43: ...ion from tl1e Voltage Sensing Board 4 Inside the control box locate the ECU and position the HertzlFrequency dip switch in the correct position for the HertzlFrequency desired S Verify all connections...

Page 44: ...This is the case of a generator equipped with auxiliary winding for regulator supply Supply is always connected to tenninals 3 and 5 of the regulator 0 I 1 I 4 3A 4 _J 2 1 EXCITER FIELD I In both of t...

Page 45: ...load protection This protection system has an intervention delay which permits a temporary overload necessary when starting motors or similar applications To modify this protection you must overload t...

Page 46: ...AL WIRING SCHEMATIC EXCITER ROTOR ROTATING FIELD TRANSIENT I I EXCITER ROTOR WINDINGS 6 l I f 1 DlOOE f O i I I I 1 I I FIELO EXCITER ROTOR WINDINGS A B c ISOLATION DIODE PLATES GREEN Engines Generato...

Page 47: ...e vesselbeing operated maycause damage to the excitercircuit components in thegenerator Shore Power Connections 60 Hertz GENERATOR NG1G2 1 I I I t S ilL r 3 __ Ship 10 Shore Swllch 3 Pole I I I I I I...

Page 48: ...such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any spilled fue...

Page 49: ...that the transmission vent is open For additional information refer to the TRANSMISSION SECTION Spare Parts Lay up time provides a good opportunity to inspect your Westerbeke engine to see if external...

Page 50: ...264 Gallons MASS WEIGHT Ounces oz x 28 35 Grams g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912...

Page 51: ...CARRYING BAG SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising KIT A...

Page 52: ...the other back to the engine return Install the remote expansion tank in a convenient location so the coolant level can easily be checked The remote expansion tank will now serve as a check and syste...

Page 53: ...Engines Generators...